Process for imprinting a composite ventilated rib

ABSTRACT

A method of forming a composite rib for the barrel of a firearm is provided. The method generally includes aligning composite material and a release layer and directing the combination of materials through a die. The release layer is removed from the intermediate rib leaving a three-dimensional finish formed in the surface of the rib.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 10/939,175,filed Sep. 10, 2004, now U.S. Pat No. 7,059,078 which claims the benefitof U.S. Provisional Application No. 60/501,685, filed Sep. 10, 2003,both applications being incorporated by reference as if set forth hereinin their entireties.

TECHNICAL FIELD

The present invention generally relates to composite pultrusions and inparticular, to imprinting a composite ventilated rib for firearms.

BACKGROUND

Firearms, such as pistols and rifles, typically include a ventilated ribmounted on the barrel. Finishing of the outer surface of the ventilatedrib is conventionally carried out by machining the rib. Machining thesurface of the rib generally is acceptable for ventilated ribs made frommetals, such as steel or aluminum. However, when the ventilated rib isformed of a composite material containing reinforcing fibers, machiningthe outer surface of the rib can remove resin and expose fibers at therib's surface. Nonetheless, finishing of particularly the top surface ofthe rib is necessary to prevent light from reflecting across the topsurface, which could impair the shooter's view of the sight and target.

Consequently, there is a need for a method for finishing or imprintingthe surface of a composite ventilated rib.

SUMMARY

Briefly described, the present invention generally is directed to amethod for forming a composite rib for a firearm such as a pistol, rifleor other long gun and imparting a three-dimensional finish to thesurface of such a composite firearm rib.

In one aspect of the present invention, a method of forming a compositerib for a firearm is provided in which a release layer is aligned with acomposite material, after which the release layer and composite materialare protruded or extruded through a die to form a composite intermediaterib. The method also includes removing the release layer from thesurface of the intermediate rib to which it has been applied, leaving athree-dimensional finish formed in the surface of the intermediate rib.Thereafter, the intermediate rib will be cut or trimmed to apredetermined length to form a rib for mounting to a barrel of afirearm.

In another aspect of the present invention, the method of forming acomponent of a firearm can comprise extruding or pultruding acombination of the release layer and the composite material through adie to form an intermediate part, and thereafter separating the releaselayer from a surface of the intermediate part leaving a finish formed inthe surface. The method also includes reducing the intermediate part toa predetermined size to fit a firearm.

As a further alternative, the rib could be formed with the formation ofa composite barrel or barrel section as an integral part thereof.

These and other aspects of the disclosure are set forth in greaterdetail in the detailed description below and the drawings, which arebriefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a ventilated rib for a firearm made accordingto a method that includes aspects of the present invention.

FIG. 2 is a top view of the ventilated rib of FIG. 1.

FIG. 3 is a front end view of the ventilated rib of FIG. 1.

FIG. 4 is a cross-sectional view of the rib of FIG. 1 taken along lineA-A.

FIG. 5 is a top view of a portion of a release layer usable in a methodthat includes aspects of the present invention.

FIG. 6 is a perspective view of an intermediate rib and the releaselayer of FIG. 5.

FIG. 7 is a cross-sectional view a combination of a rib and releaselayer usable in a method that includes aspects of the present invention.

DETAILED DESCRIPTION

Referring now to the drawings in which like reference numerals indicatelike parts throughout the several views, FIGS. 1-7 illustrate featuresthat are used in or produced by the methods of the present invention,which generally comprises methods of finishing one or more surfaces of acomposite rib 10 for the barrel of a firearm, such as a pistol, rifle,shotgun or other long guns. The composite rib 10, which is shown as aventilated rib in FIGS. 1 and 2, but which also can be unventilated orsolid, includes a finish 50 formed or imprinted along one or moreexterior surfaces, illustrated as the top surface 12 for purposes ofillustration. The finish 50 can be a weave pattern to create a mattefinish or any other pattern desirable, such as lettering, designs,shapes or other indicia.

The design generally is created by a release layer 70, which can be inthe form of a strip or a ribbon and which has the desired finish orpattern imprinted or formed therein. The release layer 70 imparts thefinish 50 to the composite rib 10 when the release layer 70 and thecomposite material used to form the composite rib 10 are directedthrough a die to form an intermediate rib 20. After pultrusion throughthe die, the release layer 70 can be removed from the intermediate rib20 leaving the finish design formed in the top surface 12 thereof. Theintermediate rib 20 can be machined, reduced and further processed orfinished to form the composite rib 10 having the finish 50 formedthereon. The strength of the composite generally is not affected by therelease layer and/or its removal from the rib, nor are there changes todesign, size and placement of the reinforcing fibers within thecomposite rib from removal of the release layer, which leaves a surfacefinish 50 imprinted on the rib.

The ventilated rib 10 generally is manufactured using a continuouspultrusion process and can be formed as a separate, individualcomponent, as illustrated in the drawings and discussed below. It willalso be understood that the rib can be formed as an integral part orcomponent of a composite barrel, such as disclosed in U.S. patentapplication Ser. No. 10/920,929, filed Aug. 18, 2004, which isincorporated herein by reference.

The rib 10 generally is formed of a composite material that includes oneor more reinforcing fibers and a resin. The reinforcing fibers can beselected from glass, carbon, or polymeric fibers which can impartstrength to the rib. For example, the reinforcing fibers can includeglass fibers having 250 roving and 32 ends produced by Owens/Corning,and carbon fibers having 250 yield roving and one end. The reinforcingfibers generally are distributed in a resin matrix. The resin caninclude any conventional resin typically used in making compositematerials. For example, the resin can be a vinyl ester, such asInterplastic 8182 or Hetron LB6875 from Ashland Chemical. The compositematerial has a glass content of about 60% to about 65% by weight and aresin content of about 35% to about 40% by weight. The density of thecomposite can be in a range of about 0.065 to about 0.075 pounds percubic inch.

One or more surface veils 32 and 33 generally are applied to thecomposite material to form a boundary layer 35 that provides andasthetically appealing surface to the composite component. The boundarylayer can be about 11 mils thick and typically is black, although othercolors and thicknesses are contemplated.

The release layer 70 can have a grosgrain black finish and be about 0.31inches wide with sizing. For example, the release layer 70 can be a #674Special Ribbon from American Ribbon.

The method generally includes providing a composite material, such asthe material shown in FIG. 7 that includes glass rovings 34 and carbonrovings 36 orientated such that the carbon roving 36 is embedded in theglass rovings 34 and generally aligned in a parallel direction. Theglass and carbon rovings 34 and 36 are “wet-out” in a bath of thermosetresin, such as polyester or vinylester. The surfacing veils 33 and 32are aligned around the rovings 34 and 36 to form a boundary layer 35,while the release layer 70 generally is aligned adjacent the boundarylayer 35. The combination of the release layer 70, boundary layer 35,resin and rovings 34 and 36 then are fed through the die of a pultrusionsystem or mechanism and is heated to about 225-320° F., for example 280°F. The cured resin is then pulled at 6 to 28 inches per minute (althoughother, lesser or greater rates also can be used as desired and dependingon the materials used) through the die with either hydraulic orcaterpillar style pullers to form an intermediate rib or component 20.The intermediate rib 20 typically then is cut to length and the releaselayer 70 is removed. Once the release layer 70 is removed, the mattingpattern remains permanently formed on the rib. The intermediate rib 20is machined to form the ventilations 14 and the barrel seat radius 16 toform the composite rib for use on the barrel of a firearm.

The method also can include forming the release layer 70 to impart thefinish or pattern therein. For example, where the release layer 70 is aribbon form from woven fibers. The method can include the step ofweaving of the release layer. In one example, the release layer 70 iswoven in a grosgrain pattern which gives the desired cosmetic effect tothe top surface 12 of the composite rib 10. After imparting the patternin the release layer 70, the layer can be sized by impregnating it withsizing agents, such as starch. The sizing is necessary to prevent theresin of the composite from “wetting-out” the release layer 70. Therelease layer 70 is sized when the components of the layer are of thetype that could absorb the resin, such as, for example, cellulosicmaterials, such as cotton, wool, and rayon. The sizing prevents theresin from absorbing into the release layer 70, thereby allowing thelayer to be removed easily from the top 12 of the intermediate rib 20.The texture, thickness and pattern of the ribbon are used to determinethe matting pattern which remains. Other materials besides cellulosicmaterials can be used to form the release layer 70. For example, mylar,polyester, nylon, and aramid materials or fibers can be included in therelease layer. The pattern, texture, thickness and or text further maybe altered to leave various corresponding patterns or designs on theresultant pultrusion.

The patterns formed using the present invention generally are onlylimited by the capability of the ribbon weaving process applied to thethin sheet which is then placed over the bonded surface. The depth andwidth of the ribs in the cross grain weave are almost infinitelyvariable, insofar as the weaver is concerned. This flexibility can allowa protruded surface to be cosmetically altered with either a pattern ortext.

In addition to thin sheets, further materials can be introduced whichcan be molded or produced in a variety of shapes, patterns or text andthen inserted into a protruded component and then removed to leave theshape of the insert in the protruded part.

The present process eliminates the need to perform secondary machiningoperations which may be required to place insignia or designs on the gunbarrel. The process provides the ability to add text to the protrusionthat would otherwise have to be added to the surface of the secondaryprocess.

It is to be understood that the above examples of are provided forillustration and are not to be construed to limit the scope of thedisclosure. The disclosure encompasses modifications and alterationsmade by those of ordinary skill in the art to the disclosed examples.

1. A method of forming a firearm component, comprising: pultruding orextruding a combination of a release layer and a composite materialthrough a die to form an intermediate firearm part; and separating therelease layer from a surface of the intermediate part, wherein thesurface of the intermediate firearm part has a three-dimensional finishformed therein.
 2. The method of claim 1, wherein directing thecombination of the release layer and the composite material through thedie to form the intermediate firearm part comprises forming a firearmrib.
 3. The method of claim 2, further comprising providing a boundarylayer between the release layer and the composite material.
 4. Themethod of claim 3, further comprising finishing the intermediate part toform the firearm component.
 5. The method of claim 2, wherein therelease layer has a pattern or indicia formed therein.
 6. The method ofclaim 2, wherein the finish is a finish formed in a surface of the rib.7. The method of claim 6, wherein the release layer has a pattern orindicia formed therein.
 8. The method of claim 1, further comprisingproviding a boundary layer material between the release layer and thecomposite material.
 9. The method of claim 1, wherein the release layerhas a pattern or indicia formed therein.
 10. The method of claim 1,further comprising finishing the intermediate part to form the firearmcomponent.
 11. The method of claim 10, further comprising providing aboundary layer material between the release layer and the compositematerial.